Post conversion nonwovens processing

ABSTRACT

A method of treated a nonwoven substrate after the normal conversion process to generate modification to the Z dimension. The method can be accomplished either before or after placing the substrate in a consumer container. The method can be accomplished by the consumer. The treatment can be the application of heat to increase the thickness of the substrate. The result can be a product combination of a canister containing a roll of wipes where the thickness of the wipes is enhanced prior to loading with a cleaning formulation.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to manufacturing post-treatment of nonwoven substrates. The present invention relates generally to consumer post- treatment of nonwoven substrates. The invention also relates to treatment of nonwoven substrates in consumer packaging containers. The invention also relates to cleaning substrates, cleaning heads, cleaning pads, cleaning sponges and related systems.

2. Description of the Related Art

U.S. Pat. App. 2004/0106345 to Zafiroglu discloses a laminated multilayer textured composite formed by a simultaneous pressure embossing and thermal laminating process. U.S. Pat. No. 6,809,048 to Jacobs discloses a heating process for forming a three-dimensional nonwoven laminate. U.S. Pat. No. 6,561,354 to Fereshtehkhou et al. describes a three-dimensional cleaning sheet formed when a contractable scrim material is heated and then cooled. U.S. Pat. No. 6,723,416 to Groitzsch et al. discloses a three-dimensional nonwoven formed from a heated shrinkage process. U.S. Pat. No. 6,774,070 to Kenmochi et al. discloses a nonwoven from core-sheath fibers. U.S. Pat. No. 6,187,699 to Terakawa et al. discloses nonwoven laminated by thermal fusion of the layers. U.S. Pat. No. 6,506,695 to Gardner et al. discloses a nonwoven web and film laminate with deformations in the film formed by heat and pressure. U.S. Pat. No. 6,270,875 to Nissing discloses a multilayer wipe that changes thickness when wetted.

These processes generally form a textured substrate while the substrate is moving along the production line in a continuous fashion. The increase in texture comes at a sacrifice to line speed, since generally the line must run at a slower speed in order to control the texturing operation. It is therefore an object of the present invention to provide a nonwoven substrate that overcomes the disadvantages and shortcomings associated with prior art substrates and related systems.

SUMMARY OF THE INVENTION

In accordance with the above objects and those that will be mentioned and will become apparent below, one aspect of the present invention comprises a product combination for delivering a nonwoven product to a consumer comprising;

-   -   a. a consumer container; and     -   b. a roll of nonwoven substrate;     -   c. wherein the nonwoven substrate has a Z-dimension thickness A         when placed in the consumer container;     -   d. wherein the nonwoven substrate is treated in the consumer         container to modify the Z-dimension thickness to give a         Z-dimension thickness B.     -   e. wherein the Z-dimension thickness B is greater than the         Z-dimension thickness A as a result of the treatment operation;         and     -   f. wherein the treatment operation is not adding a liquid to the         substrate in the consumer container.

In accordance with the above objects and those that will be mentioned and will become apparent below, another aspect of the present invention comprises a method of increasing the Z-dimension thickness of a nonwoven substrate used for a cleaning wipe comprising:

-   -   a. slitting the substrate; and     -   b. heating the substrate resulting in a modification of the         Z-dimension of the substrate.

In accordance with the above objects and those that will be mentioned and will become apparent below, another aspect of the present invention comprises a method of modifying a specific attribute of a nonwoven substrate comprising:

-   -   a. placing the substrate in a consumer container; and     -   b. treating the substrate to modify the specific attribute;     -   c. wherein the treatment is not adding a liquid to the substrate         in the consumer container.

Further features and advantages of the present invention will become apparent to those of ordinary skill in the art in view of the detailed description of preferred embodiments below, when considered together with the attached claims.

DETAILED DESCRIPTION OF THE INVENTION

Before describing the present invention in detail, it is to be understood that this invention is not limited to particularly exemplified systems or process parameters that may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments of the invention only, and is not intended to limit the scope of the invention in any manner.

All publications, patents and patent applications cited herein, whether supra or infra, are hereby incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference.

As used herein and in the claims, the term “comprising” is inclusive or open-ended and does not exclude additional unrecited elements, compositional components, or method steps. Accordingly, the term “comprising” encompasses the more restrictive terms “consisting essentially of” and “consisting of”.

It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a “surfactant” includes two or more such surfactants.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although a number of methods and materials similar or equivalent to those described herein can be used in the practice of the present invention, the preferred materials and methods are described herein.

In the application, effective amounts are generally those amounts listed as the ranges or levels of ingredients in the descriptions, which follow hereto. Unless otherwise stated, amounts listed in percentage (“%'s”) are in weight percent (based on 100% active) of the cleaning composition alone, not accounting for the substrate weight. Each of the noted cleaner composition components and substrates is discussed in detail below.

As used herein, the term “substrate” is intended to include any material that is used to treat a surface, for example, to clean an article or a surface. A wide variety of materials can be used as the substrate. The substrate should have sufficient wet strength, abrasivity, loft and porosity. Examples of suitable substrates include, nonwoven substrates, wovens substrates, hydroentangled substrates, foams and sponges. The substrate can be attached to a cleaning implement, such as a floor mop, handle, or a hand held cleaning tool, such as a toilet-cleaning device.

As used herein the term “polymer” generally includes but is not limited to, homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, etc. and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible geometrical configurations of the material. These configurations include, but are not limited to isotactic, syndiotactic and random symmetries. As used herein the term “thermoplastic” or “thermoplastic polymer” refers to polymers that will soften and flow or melt when heat and/or pressure are applied, the changes being reversible.

As used herein, “film” refers to a polymer film including flat nonporous films, and porous films such as microporous, nanoporous, closed or open celled, breathable films, or apertured films.

As used herein, the term “fiber” includes both staple fibers, i. e., fibers which have a defined length between about 2 and about 20 mm, fibers longer than staple fiber but are not continuous, and continuous fibers, which are sometimes called “continuous filaments” or simply “filaments”. The method in which the fiber is prepared will determine if the fiber is a staple fiber or a continuous filament.

As used herein, where a nonwoven includes fibers, the terms “nonwoven” or “nonwoven substrate” means a substrate having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted web. Nonwoven substrates also include films. Nonwoven substrates have been formed from many processes, such as, for example, meltblowing processes, spunbonding processes, and bonded carded web processes. The basis weight of nonwoven substrates is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm) and the fiber diameters useful are usually expressed in microns, or in the case of staple fibers, denier. It is noted that to convert from osy to gsm, multiply osy by 33.91.

The term “denier” is defined as grams per 9000 meters of a fiber. For a fiber having circular cross-section, denier may be calculated as fiber diameter in microns squared, multiplied by the density in grams/cc, multiplied by 0.00707. A lower denier indicates a finer fiber and a higher denier indicates a thicker or heavier fiber. Outside the United States the unit of measurement is more commonly the “tex,” which is defined as the grams per kilometer of fiber. Tex may be calculated as denier divided by 9. The “mean fiber denier” is the sum of the deniers for each fiber, divided by the number of fibers.

As used herein, the term “bulk density” refers to the weight of a material per unit of volume and is generally expressed in units of mass per unit bulk volume (e.g., grams per cubic centimeter).

As used herein, the term “spunbonded fibers” refers to fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced as by, for example, U.S. Pat. No. 4,340,563 to Appel et al., and U.S. Pat. No. 3,692,618 to Dorschner et al., U.S. Pat. No. 3,802,817 to Matsuki et al., U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Pat. No. 3,502,763 to Hartman; U.S. Pat. No. 3,542,615 to Dobo et al.; and U.S. Pat. No. 5,382,400 to Pike et al.; the entire content of each is incorporated herein by reference. Spunbond fibers are generally not tacky when they are deposited onto a collecting surface. Spunbond fibers are generally continuous and have average diameters (from a sample of at least 10) larger than 7 microns to about 50 or 60 microns, often, between about 15 and 25 microns.

As used herein, the term “meltblown fibers” means fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity, usually hot, gas (e.g. air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly dispersed meltblown fibers. Such a process is disclosed, for example, in U.S. Pat. No. 3,849,241. Meltblown fibers can be microfibers, which may be continuous or discontinuous, and are generally smaller than 10 microns in average diameter, and are generally tacky when deposited onto a collecting surface.

As used herein, the term “conjugate fibers” refers to fibers or filaments that have been formed from at least two polymers extruded from separate extruders but spun together to form one fiber. Conjugate fibers are also sometimes referred to as “multicomponent” or “bicomponent” fibers or filaments. The term “bicomponent” means that there are two polymeric components making-up the fibers. The polymers are usually different from each other though conjugate fibers may be prepared from the same polymer, but the polymers are different from one another in some physical property, such as, for example, melting point or the softening point. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the multicomponent fibers or filaments and extend continuously along the length of the multicomponent fibers or filaments. The configuration of such a multicomponent fiber may be, for example, a sheath/core arrangement, wherein one polymer is surrounded by another, a side-by-side arrangement, a pie arrangement or an “islands-in-the-sea” arrangement. Multicomponent fibers are taught in U.S. Pat. No. 5,108,820 to Kaneko et al., U.S. Pat. No. 5,336,552 to Strack et al., and U.S. Pat. No. 5,382,400 to Pike et al., the entire content of each is incorporated herein by reference. For two component fibers or filaments, the polymers may be present in ratios of 75/25, 50/50, 25/75 or any other desired ratios.

As used herein, the term “multiconstituent fibers” refers to fibers that have been formed from at least two polymers extruded from the same extruder as a blend or mixture. Multiconstituent fibers do not have the various polymer components arranged in relatively constantly positioned distinct zones across the cross-sectional area of the fiber and the various polymers are usually not continuous along the entire length of the fiber, instead usually forming fibrils or protofibrils which start and end at random.

As used herein “carded webs” refers to nonwoven webs formed by carding processes as are known to those skilled in the art and further described, for example, in U.S. Pat. No. 4,488,928 to Alikhan and Schmidt, which is incorporated herein in its entirety by reference. Briefly, carding processes involve starting with staple fibers in a bulky batt that is combed or otherwise treated to provide a web of generally uniform basis weight. As used herein “Bonded carded web” refers to webs that are made from staple fibers which are sent through a combing or carding unit, which breaks apart and aligns the staple fibers in the machine direction to form a generally machine direction-oriented fibrous nonwoven web. Such fibers are usually purchased in bales and are placed in a picker, which separates the fibers prior to the carding unit. Once the web is formed, it then is bonded by one or more of several known bonding methods. One such bonding method is powder bonding, wherein a powdered adhesive is distributed through the web and then activated, usually by heating the web and adhesive with hot air. Another suitable bonding method is pattern bonding, wherein heated calender rolls or ultrasonic bonding equipment are used to bond the fibers together, usually in a localized bond pattern, though the web can be bonded across its entire surface if so desired. Another suitable and well-known bonding method, particularly when using conjugate staple fibers, is through-air bonding.

As used herein, the term “hot air knife” or HAK means a process of bonding a just produced web, particularly spunbond, in order to give it sufficient integrity, i.e. increase the strength of the web, for further processing. A hot air knife is a device which focuses a stream of heated air at a very high flow rate, generally from about 1000 to about 10000 feet per minute (fpm) (305 to 3050 meters per minute), or more particularly from about 3000 to 5000 feet per minute (915 to 1525 m/min.) directed at the nonwoven web after its formation. The air temperature is usually in the range of the melting point of at least one of the polymers used in the web, generally between about 200 and 550° F. (93 and 290° C.) for the thermoplastic polymers commonly used in spunbonding. The control of air temperature, velocity, pressure, volume and other factors helps avoid damage to the web while increasing its integrity. The HAK process has a great range of variability and controllability of many factors such as air temperature, velocity, pressure, volume, slot or hole arrangement and size, and the distance from the HAK plenum to the web.

As used herein, through-air bonding or “TAB” means a process of bonding a nonwoven bicomponent fiber web in which air, which is sufficiently hot to melt one of the polymers of which the fibers of the web are made is forced through the web. The air velocity is between 100 and 500 feet per minute and the dwell time may be as long as 6 seconds. The melting and resolidification of the polymer provides the bonding. Through air bonding has relatively restricted variability and since through-air bonding TAB requires the melting of at least one component to accomplish bonding and is therefore particularly useful in connection with webs with two components like conjugate fibers or those which include an adhesive. In the through-air bonder, air having a temperature above the melting temperature of one component and below the melting temperature of another component is directed from a surrounding hood, through the web, and into a perforated roller supporting the web. Alternatively, the through-air bonder may be a flat arrangement wherein the air is directed vertically downward onto the web. The operating conditions of the two configurations are similar, the primary difference being the geometry of the web during bonding. The hot air melts the lower melting polymer component and thereby forms bonds between the filaments to integrate the web.

As used herein, “ultrasonic bonding” means a process performed, for example, by passing the fabric between a sonic horn and anvil roll as illustrated in U.S. Pat. No. 4,374,888 to Bornslaeger. As used herein “thermal point bonding” involves passing one or more layers to be bonded between a heated engraved pattern roll and a smooth calender roll. The engraved roll is, patterned in some way so that the entire fabric is not bonded over its entire surface, and the anvil roll is usually flat. As a result, various patterns for engraved rolls have been developed for functional as well as aesthetic reasons. One example of a pattern has points and is the Hansen Pennings or “H &P” pattern with about a 30% bond area when new and with about 200 bonds/square inch as taught in U.S. Pat. No. 3,855,046 to Hansen and Pennings. The H &P pattern has square point or pin bonding areas wherein each pin has a side dimension of 0.038 inches (0.965 mm), a spacing of 0.070 inches (1.778 mm) between pins, and a depth of bonding of 0.023 inches (0.584 mm). The resulting pattern has a bonded area of about 29.5% when new. Another typical point bonding pattern is the expanded Hansen Pennings or “EHP” bond pattern, which produces a 15% bond area when new with a square pin having a side dimension of 0.037 inches (0.94 mm), a pin spacing of 0.097 inches (2.464 mm) and a depth of 0.039 inches (0.991 mm). Another typical point bonding pattern designated “714” has square pin bonding areas wherein each pin has a side dimension of 0.023 inches, a spacing of 0.062 inches (1.575 mm) between pins, and a depth of bonding of 0.033 inches (0.838 mm). The resulting pattern has a bonded area of about 15% when new. Yet another common pattern is the C-Star pattern, which has, when new, a bond area of about 16.9%. The C-Star pattern has a cross-directional bar or “corduroy” design interrupted by shooting stars. Other common patterns include a diamond pattern with repeating and slightly offset diamonds with about a 16% bond area and a wire weave pattern looking as the name suggests, e.g. like a window screen, with about a 15% bond area. Typically, the percent bonding area varies from around 10% to around 30% of the area of the fabric laminate web. As is well known in the art, the spot bonding holds the laminate layers together as well as imparts integrity to each individual layer by bonding filaments and/or fibers within each layer.

As used hereing “airlaying” or “airlaid” is a well-known process by which a fibrous nonwoven layer can be formed. In the airlaying process, bundles of small fibers having typical lengths ranging from about 3 to about 52 millimeters (mm) are separated and entrained in an air supply and then deposited onto a forming screen, usually with the assistance of a vacuum supply. The randomly deposited fibers then are bonded to one another using, for example, hot air to activate a binder component or a latex adhesive. Airlaying is taught in, for example, U.S. Pat. No. 4,640,810 to Laursen et al., and U.S. Pat. No. 5,885,516 to Christensen.

The term “sponge”, as used herein, is meant to mean an elastic, porous material, including, but not limited to, compressed sponges, cellulosic sponges, reconstituted cellulosic sponges, cellulosic materials, foams from high internal phase emulsions, such as those disclosed in U.S. Pat. No. 6,525,106, polyethylene, polypropylene, polyvinyl alcohol, polyurethane, polyether, and polyester sponges, foams and nonwoven materials, and mixtures thereof.

As used herein, the term “machine direction” or MD means the length of a fabric in the direction in which it is produced. The term “cross machine direction” or CD means the width of fabric, i.e. a direction generally perpendicular to the MD.

As used herein, the term “Z-dimension” refers to the dimension orthogonal to the length and width of the cleaning sheet of the present invention, or a component thereof. The Z-dimension usually corresponds to the thickness of the sheet. As used herein, the term “X-Y dimension” refers to the plane orthogonal to the thickness of the cleaning sheet, or a component thereof. The X and Y dimensions usually correspond to the length and width, respectively, of the sheet or a sheet component. In one embodiment of the invention, the substrates undergo processing to expand the fibrous web in the z-direction to increase the bulk and thickness of the web while maintain a low basis weight. The Z-direction expansion of the substrates of the present invention may reduce the density of the web in two dissimilar ways: overall density and localized density. Overall density is calculated by, 1) measuring the overall caliper of the web over a large area (i.e. ˜25 cm²), and 2) dividing the basis weight (in grams per cm²) by the caliper (in cm) to yield the density in g/cc. Localized density is determined in a similar manner except that the caliper is the average of the thinnest portion of the web measured perpendicular to the surface of said web portion.

The caliper of a substrate is a measure of its thickness. The overall caliper of a substrate is a measurement of the highest to lowest point on a substrate and the local caliper is a measurement of the thickness of the substrate at a given point. The substrate of the present invention may be flat, where the local caliper is substantially equal to the overall caliper or it may be textured where the local caliper and the overall caliper have substantially different values. In a preferred embodiment of the invention, the fibrous web has a local caliper that is less than about 10% to 75% of the overall caliper. The overall caliper measurement was performed at a pressure of 0.01 psi. Any caliper measurement equipment capable of measuring at this pressure should be suitable for measuring the overall caliper. The SDL Atlas Digital Thickness Gauge, Model # M034A is another effective tool for measuring these calipers. The local caliper is best measured using a microscope without applying any pressure to the substrate. Thickness A is the substrate thickness prior to final processing and thickness B is the substrate thickness after final processing, as defined herein.

Various processes can be utilized to achieve Z-direction expansion. One type of process decreases both overall density and local density. A second set of processes decreases the overall density without significantly altering the local density. Processes that belong to the first group include, but are not limited to, bulking via abrasion, air texturing, heat activation to bulk by gathering with blends of fibers and/or bicomponent fibers, or combinations thereof. Processes that belong to the second group move the fibrous web center-line out of the X-Y dimension and include, but are not limited to: thermoforming, bicomponent heat shrinking, convoluted forming wires, male-male mated rolls, embossing rolls, “SpaceNet”, ring-rolling, SELFing, and/or combinations thereof.

The processes for thermoforming, using forming wires or forming surfaces to create texture in a non-woven is well known in the art. The non-woven materials formed around a textured wire or forming surface using heat to shape the fibers into place. Similarly, embossing or heated male-male mated rolled with interlocking dual pin rolls use heat and/or pressure to create textured non-woven materials and are also widely used in the art.

As used herein, the term “layer” refers to a member or component of a cleaning sheet whose primary dimension is X-Y, i.e., along its length and width. It should be understood that the term layer is not necessarily limited to single layers or sheets of material. Thus the layer can comprise laminates or combinations of several sheets or webs of the requisite type of materials. Accordingly, the term “layer” includes the terms “layers” and “layered.”

For purposes of the present invention, an “upper” layer of a cleaning sheet is a layer that is relatively further away from the surface that is to be cleaned (i.e., in the implement context, relatively closer to the implement handle during use). The term “lower” layer conversely means a layer of a cleaning sheet that is relatively closer to the surface that is to be cleaned (i.e., in the implement context, relatively further away from the implement handle during use).

The term “cleaning composition”, as used herein, is meant to mean and include a cleaning formulation having at least one surfactant.

The term “surfactant”, as used herein, is meant to mean and include a substance or compound that reduces surface tension when dissolved in water or water solutions, or that reduces interfacial tension between two liquids, or between a liquid and a solid. The term “surfactant” thus includes anionic, nonionic and/or amphoteric agents.

As used herein, the term “garment” means any type of non-medically oriented apparel which may be worn. This includes industrial work wear and coveralls, undergarments, pants, shirts, jackets, gloves, socks, and the like.

As used herein, the term “infection control product” means medically oriented items such as surgical gowns and drapes, face masks, head coverings like bouffant caps, surgical caps and hoods, footwear like shoe coverings, boot covers and slippers, wound dressings, bandages, sterilization wraps, wipers, garments like lab coats, coveralls, aprons and jackets, patient bedding, stretcher and bassinet sheets, industrial coveralls, and the like.

As used herein, the term “personal care product” means diapers, training pants, absorbent underpants, adult incontinence products, and feminine hygiene products.

Post-Treatment

The substrate may be post-treated in a roll, in stacks of individual sheets, or after forming individual structures, such as diapers or mitts. The substate may be post-treated after it has been slit and is still on the process line. The substate may be post-treated after it has been placed in a packaging or consumer use container. The substrate may be post-treated by the consumer.

One suitable form of post-treatment is heating the substrate. The substrate can be heated by a variety of forms of energy. Suitable forms of energy include, but are not limited to, heat, ultrasound, electromagnetic, hydrodynamic, and aerodynamic energy. Types of electromagnetic energy forms include but are not limited to ultraviolet light, infrared light, radio-frequency waves, microwaves, and electron beam. The post-treatment of the substrate results in activation of the substrate to modify a specific attribute of the substrate. Types of activation of components of starting substrate include, but are not limited to, melting, cross-linking, polymerization, chemical bonding, and ionic bonding. In a suitable embodiment, rolls or sheets or individual items of substrate are heated to about the melting temperature of one of the components of the starting substrate. After the heated substrate has cooled, a specific attribute of the substrate, such as thickness, has been modified. The final attribute may differ along the substrate depending upon the substrate properties, for example, the bonding pattern.

Nonwoven Substrate and Processing

In one embodiment, the substrate of the present invention comprises a nonwoven substrate or web. The substrate is composed of nonwoven fibers or paper. The term nonwoven is to be defined according to the commonly known definition provided by the “Nonwoven Fabrics Handbook” published by the Association of the Nonwoven Fabric Industry. A paper substrate is defined by EDANA (note 1 of ISO 9092-EN 29092) as a substrate comprising more than 50% by mass of its fibrous content is made up of fibers (excluding chemically digested vegetable fibers) with a length to diameter ratio of greater than 300, and more preferably also has density of less than 0.040 g/cm³. The definitions of both nonwoven and paper substrates do not include woven fabric or cloth or sponge. The substrate can be partially or fully permeable to water. The substrate can be flexible and the substrate can be resilient, meaning that once applied external pressure has been removed the substrate regains its original shape.

The substrates of the present invention are formed by any of the following processes: carding, airlaid, spunbond, meltblown, coform, wetlaid, and mixtures thereof. The substrates of the present invention are consolidated by any of the following processes: hydroentanglement, thermal calender bonding, through air thermal bonding, chemical bonding, needlepunching, and mixtures thereof. The air-laying process is described in U.S. Pat. App. 2003/0036741 to Abba et al. and U.S. Pat. App. 2003/0118825 to Melius et al. The resulting layer, regardless of its method of production or composition, is then subjected to at least one of several types of bonding operations to anchor the individual fibers together to form a self-sustaining substrate. In the present invention the nonwoven substrate can be prepared by a variety of processes including, but not limited to, air-entanglement, hydroentanglement, thermal bonding, and combinations of these processes.

Additionally, the first layer and the second layer, as well as additional layers, when present, can be bonded to one another in order to maintain the integrity of the article. The layers can be heat spot bonded together or using heat generated by ultrasonic sound waves. The bonding may be arranged such that geometric shapes and patterns, e.g. diamonds, circles, squares, etc., are created on the exterior surfaces of the layers and the resulting article.

The bonding pattern can be chosen in order to maximize stiffness of the substrate. This applies in particular when bonding is effected by adhesive (chemical, such as epoxy resin adhesive, or other adhesive) or by ultrasound. Thermal or pressure bonding can be used if the layers to be bonded are appropriate for this. One suitable bonding pattern is application of adhesive or ultrasonic bonding across the full area of the substrate. Generally such patterns do not take up substantially the entire area, sometimes not more than 20%, sometimes not more than 15%, but sometimes at least 5%, of the area of the substrate is covered by bonds.

One suitable application pattern for adhesive, ultrasonic or other bonds is in the form of a number of stripes extending across the width of the substrate. Suitably the stripes are parallel. The direction can be chosen depending upon the direction in which stiffness is desired. For instance, if stiffness in the machine direction (this direction being defined in relation to the manufacturing process for the substrate) is desired, i.e. it is desired to make folding along a line extending in the transverse direction more difficult, then the stripes can extend in the machine direction. Conversely, if transverse direction stiffness is desired, then stripes extending in the transverse direction can be provided. A particularly bonding pattern is one of two sets of parallel stripes at different angles, for instance in cross-hatch form. Such systems can provide the effect of introduction of a net between two layers.

The above patterns for improvement of stiffness are useful when applied to adhesive or ultrasound bonding. However, such patterns can alternatively be applied using hot melt polymer printed onto the substrate, either between layers or on an exterior surface of one of the layers. Such patterns can be applied using any low melting polymer that is flexible after application and drying and capable of producing a continuous film. Suitable polymers include polyethylene. Application of hot melt polymer can be for instance by screen or gravure printing. Screen printing is preferred. Application of hot melt polymer can be on an exterior surface on one of the layers.

Bonding can be effected after all layers intended to form the substrate have been assembled. In some embodiments, however, two or more layers can be pre-bonded prior to contacting these layers with additional layers to form the substrate.

The stiffness of the substrate when wet is an important feature. Stiffness is expressed in Taber stiffness units, preferably measured in accordance with ASTM D-5650 (resistance to bending of paper of low bending stiffness). Stiffness of the substrate when dry is measured before it is used for cleaning a surface. Stiffness of the substrate when wet is measured after it has been saturated in water. Stiffness when dry can be at least 5, or at least 8 Taber stiffness units. In particularly cases, stiffness when dry is at least 9 Taber stiffness units. The Taber stiffness when wet can be at least 5 or at least 8. In particular embodiments, the stiffness when wet can be at least 9 Taber stiffness units. Particular embodiments have stiffness when wet at least 50% or at least 60% or at least 80% or at least 90% of stiffness when dry.

The substrate can include both natural and synthetic fibers. The substrate can also include water-soluble fibers or water-dispersible fibers, from polymers described herein. The substrate can be composed of suitable unmodified and/or modified naturally occurring fibers including cotton, Esparto grass, bagasse, hemp, flax, silk, wool, wood pulp, chemically modified wood pulp, jute, ethyl cellulose, and/or cellulose acetate. Various pulp fibers can be utilized including, but not limited to, thermomechanical pulp fibers, chemi-thermomechanical pulp fibers, chemi-mechanical pulp fibers, refiner mechanical pulp fibers, stone groundwood pulp fibers, peroxide mechanical pulp fibers and so forth.

Suitable synthetic fibers can comprise fibers of one, or more, of polyvinyl chloride, polyvinyl fluoride, polytetrafluoroethylene, polyvinylidene chloride, polyacrylics such as ORLON®, polyvinyl acetate, Rayon®, polyethylvinyl acetate, non-soluble or soluble polyvinyl alcohol, polyolefins such as polyethylene (e.g., PULPEX®) and polypropylene, polyamides such as nylon, polyesters such as DACRON® or KODEL®, polyurethanes, polystyrenes, and the like, including fibers comprising polymers containing more than one monomer.

The substrate polymers suitable for the present invention include polyolefins, polyesters, polyamides, polycarbonates, polyurethanes, polyvinylchloride, polytetrafluoroethylene, polystyrene, polyethylene terephathalate, biodegradable polymers such as polylactic acid and copolymers and blends thereof. Suitable polyolefins include polyethylene, e.g., high density polyethylene, medium density polyethylene, low density polyethylene and linear low density polyethylene; polypropylene, e.g., isotactic polypropylene, syndiotactic polypropylene, blends of isotactic polypropylene and atactic polypropylene, and blends thereof, polybutylene, e.g., poly(1-butene) and poly(2-butene); polypentene, e.g., poly(1-pentene) and poly(2-pentene); poly(3-methyl-1-pentene); poly(4-methyl 1-pentene); and copolymers and blends thereof. Suitable copolymers include random and block copolymers prepared from two or more different unsaturated olefin monomers, such as ethylene/propylene and ethylene/butylene copolymers. Suitable polyamides include nylon 6, nylon 6/6, nylon 4/6, nylon 11, nylon 12, nylon 6/10, nylon 6/12, nylon 12/12, copolymers of caprolactam and alkylene oxide diamine, and the like, as well as blends and copolymers thereof. Suitable polyesters include polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polytetramethylene terephthalate, polycyclohexylene-1,4-dimethylene terephthalate, and isophthalate copolymers thereof, as well as blends thereof.

Many other polyolefins are commercially available and generally can be used in the present invention. Suitable polyolefins are polypropylene and polyethylene. Many polyolefins are available for fiber production, for example polyethylenes such as Dow Chemical's ASPUN 6811A linear low-density polyethylene, 2553 LLDPE and 25355 and 12350 high-density polyethylene are such suitable polymers. The polyethylenes have melt flow rates in g/10 min. at 190° F. and a load of 2.16 kg, of about 26, 40, 25 and 12, respectively. Fiber forming polypropylenes include Exxon Chemical Company's ESCORENE PD3445 polypropylene.

Examples of polyamides and their methods of synthesis may be found in “Polymer Resins” by Don E. Floyd (Library of Congress Catalog number 66-20811, Reinhold Publishing, N.Y., 1966). Particularly commercially useful polyamides are nylon 6, nylon-6,6, nylon-11 and nylon-12. These polyamides are available from a number of sources such as Custom Resins, Nyltech, among others. In addition, a compatible tackifying resin may be added to the extrudable compositions described above to provide tackified materials that autogenously bond or which require heat for bonding. Any tackifier resin can be used which is compatible with the polymers and can withstand the high processing (e.g., extrusion) temperatures. If the polymer is blended with processing aids such as, for example, polyolefins or extending oils, the tackifier resin should also be compatible with those processing aids. Generally, hydrogenated hydrocarbon resins are preferred tackifying resins, because of their better temperature stability. REGALREZ® and ARKON® P series tackifiers are examples of hydrogenated hydrocarbon resins. ZONATAC® 501 lite is an example of a terpene hydrocarbon. REGALREZ® hydrocarbon resins are available from Hercules Incorporated. ARKON® series resins are available from Arakawa Chemical (USA) Incorporated. The tackifying resins such as disclosed in U.S. Pat. No. 4,787,699, hereby incorporated by reference, are suitable. Other tackifying resins that are compatible with the other components of the composition and can withstand the high processing temperatures, can also be used.

Suitable thermoplastic fibers can be made from a single polymer (monocomponent fibers), or can be made from more than one polymer (e.g., bicomponent or multicomponent fibers). Multicomponent fibers are described in U.S. Pat. App. 2003/0106568 to Keck and Arnold. Bicomponent fibers are described in U.S. Pat. No. 6,613,704 to Arnold and Myers and references therein. Multicomponent fibers of a wide range of denier or dtex are described in U.S. Pat. App. 2002/0106478 to Hayase et. al. The “bicomponent fibers” may be thermoplastic fibers that comprise a core fiber made from one polymer that is encased within a thermoplastic sheath made from a different polymer. The polymer comprising the sheath often melts at a different, typically lower, temperature than the polymer comprising the core. As a result, these bicomponent fibers provide thermal bonding due to melting of the sheath polymer, while retaining the desirable strength characteristics of the core polymer.

Suitable bicomponent fibers for use in the present invention can include sheath/core fibers having the following polymer combinations: polyethylene/polypropylene, polyethylvinyl acetate/ polypropylene, polyethylene/ polyester, polypropylene/ polyester, copolyester/ polyester, and the like. Particularly suitable bicomponent thermoplastic fibers for use herein are those having a polypropylene or polyester core, and a lower melting copolyester, polyethylvinyl acetate or polyethylene sheath (e.g., those available from Danaklon a/s, Chisso Corp., and CELBOND®, available from Hercules). These bicomponent fibers can be concentric or eccentric. As used herein, the terms “concentric” and “eccentric” refer to whether the sheath has a thickness that is even, or uneven, through the cross-sectional area of the bicomponent fiber. Eccentric bicomponent fibers can be desirable in providing more compressive strength at lower fiber thicknesses.

In suitable embodiments, it is desirable that the particular polymers used for the different components of the fibers in the practice of the invention have melting points different from one another. This is important not only in producing crimped fibers but also when through-air bonding is used as the bonding technique, wherein the lower melting polymer bonds the fibers together to form the fabric or web. It is desirable that the lower melting point polymers make up at least a portion of the outer region of the fibers. More particularly, the lower melting component should be located in an outer portion of the fiber so that it comes in contact with other fibers. For example, in a sheath/core fiber configuration, the lower melting point polymer component should be located in the sheath portion. In a side-by-side configuration, the lower melting point polymer will inherently be located on an outer portion of the fiber. Multicomponent conjugate fibers that contain two or more component polymers, and more particularly suitable fibers are multicomponent conjugate fibers containing polymers of different melting points. Suitably, the melting point difference between the highest melting polymer and the lowest melting polymer of the conjugate fibers should be at least about 5.degree. C., or about 30.degree. C., so that the lowest melting polymer can be melted without affecting the chemical and physical integrities of the highest melting polymer.

The proportion of higher and lower melting polymers in the multicomponent, multilobal fibers can range between about 10-90% by weight higher melting polymer and 10-90% lower melting polymer. In practice, only so much lower melting polymer is needed as will facilitate bonding between the fibers. Thus, a suitable fiber composition may contain about 40-80% by weight higher melting polymer and about 20-60% by weight lower melting polymer, desirably about 50-75% by weight higher melting polymer and about 25-50% by weight lower melting polymer. In one embodiment, a first polymer, which is the lower melting point polymer, is polyethylene and the higher melting point polymer is polypropylene.

The substrate can comprise solely naturally occurring fibers, solely synthetic fibers, or any compatible combination of naturally occurring and synthetic fibers. The fibers useful herein can be hydrophilic, hydrophobic or can be a combination of both hydrophilic and hydrophobic fibers. As indicated above, the particular selection of hydrophilic or hydrophobic fibers depends upon the other materials included in the absorbent (and to some degree) the scrubbing layer described hereinafter. Suitable hydrophilic fibers for use in the present invention include cellulosic fibers, modified cellulosic fibers, rayon, cotton, and polyester fibers, such as hydrophilic nylon (HYDROFIL®). Suitable hydrophilic fibers can also be obtained by hydrophilizing hydrophobic fibers, such as surfactant-treated or silica-treated thermoplastic fibers derived from, for example, polyolefins such as polyethylene or polypropylene, polyacrylics, polyamides, polystyrenes, polyurethanes and the like.

Another type of hydrophilic fiber for use in the present invention is chemically stiffened cellulosic fibers. As used herein, the term “chemically stiffened cellulosic fibers” means cellulosic fibers that have been stiffened by chemical means to increase the stiffness of the fibers under both dry and aqueous conditions. Such means can include the addition of a chemical stiffening agent that, for example, coats and/or impregnates the fibers. Such means can also include the stiffening of the fibers by altering the chemical structure, e.g., by crosslinking polymer chains.

Fibers can optionally be combined with a thermoplastic material. Upon melting, at least a portion of this thermoplastic material migrates to the intersections of the fibers, typically due to interfiber capillary gradients. These intersections become bond sites for the thermoplastic material. When cooled, the thermoplastic materials at these intersections solidify to form the bond sites that hold the matrix or web of fibers together in each of the respective layers. This can be beneficial in providing additional overall integrity to the cleaning substrate. Amongst its various effects, bonding at the fiber intersections increases the overall compressive modulus and strength of the resulting thermally bonded member. In the case of the chemically stiffened cellulosic fibers, the melting and migration of the thermoplastic material also has the effect of increasing the average pore size of the resultant web, while maintaining the density and basis weight of the web as originally formed. This can improve the fluid acquisition properties of the thermally bonded web upon initial exposure to fluid, due to improved fluid permeability, and upon subsequent exposure, due to the combined ability of the stiffened fibers to retain their stiffness upon wetting and the ability of the thermoplastic material to remain bonded at the fiber intersections upon wetting and upon wet compression. In net, thermally bonded webs of stiffened fibers retain their original overall volume, but with the volumetric regions previously occupied by the thermoplastic material becoming open to thus increase the average interfiber capillary pore size.

Thermoplastic materials useful in the present invention can be in any of a variety of forms including particulates, fibers, or combinations of particulates and fibers. Thermoplastic fibers are a particularly preferred form because of their ability to form numerous interfiber bond sites. Suitable thermoplastic materials can be made from any thermoplastic polymer that can be melted at temperatures that will not extensively damage the fibers that comprise the primary web or matrix of each layer. Suitably, the melting point of this thermoplastic material will be less than about 190° C., or between about 75° C. and about 175° C. In any event, the melting point of this thermoplastic material should be no lower than the temperature at which the thermally bonded structures are likely to be stored. The melting point of the thermoplastic material is typically no lower than about 50° C.

The surface of the hydrophobic thermoplastic fiber can be rendered hydrophilic by treatment with a surfactant, such as a nonionic or anionic surfactant, e.g., by spraying the fiber with a surfactant, by dipping the fiber into a surfactant or by including the surfactant as part of the polymer melt in producing the thermoplastic fiber. Upon melting and resolidification, the surfactant will tend to remain at the surfaces of the thermoplastic fiber. Suitable surfactants include nonionic surfactants such as Brij® 76 manufactured by ICI Americas, Inc. of Wilmington, Del., and various surfactants sold under the Pegosperse® trademark by Glyco Chemical, Inc. of Greenwich, Conn. Besides nonionic surfactants, anionic surfactants can also be used. These surfactants can be applied to the thermoplastic fibers at levels of, for example, from about 0.2 to about 1 g per square centimeter of thermoplastic fiber.

In one embodiment, the cleaning substrate has at least two regions where the regions are distinguished by basis weight. Briefly, the measurement is achieved photographically, by differentiating dark (low basis weight) and light (high basis) network regions. In particular, the cleaning substrate comprises one or more low basis weight regions, wherein the low basis region(s) have a basis weight that is not more than about 80% of the basis weight of the high basis weight regions. In one aspect, the first region is relatively high basis weight and comprises an essentially continuous network. The second region comprises a plurality of mutually discrete regions of relatively low basis weight and which are circumscribed by the high basis weight first region. In particular, a cleaning substrate may comprise a continuous region having a basis weight of from about 30 to about 120 grams per square meter and a plurality of discontinuous regions circumscribed by the high basis weight region, wherein the discontinuous regions are disposed in a random, repeating pattern and having a basis weight of not more than about 80% of the basis weight of the continuous region.

In one embodiment, the cleaning substrate will have, in addition to regions which differ with regard to basis weight, substantial macroscopic three-dimensionality. The term “macroscopic three-dimensionality”, when used to describe three dimensional cleaning substrates means a three-dimensional pattern is readily visible to the naked eye when the perpendicular distance between the viewer's eye and the plane of the substrate is about 12 inches. In other words, the three dimensional structures of the pre-moistened substrates of the present invention are cleaning substrates that are non-planar, in that one or both surfaces of the substrates exist in multiple planes. By way of contrast, the term “planar”, refers to substrates having fine-scale surface aberrations on one or both sides, the surface aberrations not being readily visible to the naked eye when the perpendicular distance between the viewer's eye and the plane of the sheet is about 12 inches. In other words, on a macro scale the observer will not observe that one or both surfaces of the substrate will exist in multiple planes so as to be three-dimensional.

Briefly, macroscopic three-dimensionality is described in terms of average height differential, which is defined as the average distance between adjacent peaks and valleys of a given surface of a substrate, as well as the average peak-to-peak distance, which is the average distance between adjacent peaks of a given surface. Macroscopic three dimensionality is also described in terms of surface topography index of the outward surface of a cleaning substrate; surface topography index is the ratio obtained by dividing the average height differential of a surface by the average peak-to-peak distance of that surface. In one embodiment, a macroscopically three-dimensional cleaning substrate has a first outward surface and a second outward surface wherein at least one of the outward surfaces has a peak to peak distance of at least about 1 mm and a surface topography index from about 0.01 mm to about 10 mm. The macroscopically three-dimensional structures of the substrates of the present invention optionally comprise a scrim, which when heated and the cooled, contract so as to provide further macroscopic three-dimensional structure.

In another embodiment, the substrate can comprise a laminate of two outer hydroentangled webs, such as nonwoven webs of polyester, rayon fibers or blends thereof having a basis weight of about 10 to about 60 grams per square meter, joined to an inner constraining layer, which can be in the form of net like scrim material which contracts upon heating to provide surface texture in the outer layers.

Chemical bonding utilizes a solvent or adhesive, and U.S. Pat. No. 3,575,749 to Kroyer discloses bonding the fibrous layer with a latex binder, which may be applied to one or both sides of the web. Binders may comprise liquid emulsions, latex binders, liquid adhesives, chemical bonding agents, and mixtures thereof. The binder composition can be made using a latex adhesive commercially available as Rovene 5550 (49 percent solids styrene butadiene) available from Mallard Creek Polymers of Charlotte, N.C. Other suitable binders are available from National Starch and Chemical, including DUR-O-SET 25-149A (Tg=+9° C.), NACRYLIC 25-012A (Tg=−34° C.), NACRYLIC 25-4401 (Tg=−23° C.), NACRYLIC ABX-30-25331A, RESYN 1072 (Tg=+37° C.), RESYN 1601, X-LINK25-033A, DUR-O-SET C310, DUR-O-SET ELITE ULTRA, (vinylacetate hompolymers and copolymers), STRUCTURECOTE 1887 (modified starch), NATIONAL 77-1864 (Tg=+100° C.)(modified starch), TYLAC NW-4036-51-9 (styrene-butadiene terpolymer), and from Air Products Polymers, including Flexbond AN214 (Tg=+30° C.)(vinylacetate copolymer). A latex emulsion or solution, typically in an aqueous medium, is applied to one or both surfaces of the web to provide a latex coating which partially impregnates the web, and upon curing stabilizes the structure. The latex may be applied to the web by any suitable means such as spraying, brushing, flooding, rolling, and the like. The amount of latex applied and the degree of penetration of the latex are controlled so as to avoid impairing the effective absorbency.

Examples of suitable nonwoven water insoluble substrates include, 100% cellulose Wadding Grade 1804 from Little Rapids Corporation, 100% polypropylene needlepunch material NB 701-2.8-W/R from American Non-wovens Corporation, and a blend of cellulosic and synthetic fibres-Hydraspun 8579 from Ahlstrom Fibre Composites. Another useful substrate is manufactured by Jacob Holm-Lidro Rough. It is a composition material comprising a 65/35 viscose rayon/polyester hydroentangled spunlace layer with a hydroenlongated bonded polyeser scribbly layer. Still another useful substrate is manufactured by Texel “TI”. It is a composite material manufactured from a layer of coarse fiber 100% polypropylene needlepunch, an absorbent cellulose core and a fine fiber polyester layer needlepunched together. The polypropylene layer can range from 1.5 to 3.5 oz/sq. yd. The cellulose core is a creped paper layer ranging from 0.5 to 2 oz./sq. yd. The fine fiber polyester layer can range from 0.5 to 2 oz./sq. yd. Still another composite material manufactured by Texcel from a layer of coarse fiber 100% polypropylene needlepunch layer, an absorbent cellulose core and a fine fiber polyester layer needlepunched together. The polypropylene layer can range from 1.5 to 3.5 oz/sq. yd. The cellulose core is a creped paper layer ranging from 0.5 to 2 oz/sq. yd. The fine fiber polyester layer can range from 0.5 to 2 oz/sq. yd. The polypropylene layer is flame treated to further increase the level of abrasivity. The temperature of the flame and the length of time the material is exposed can be varied to create different levels of surface roughness.

Ahlstrom manufactures a hydroentangled nonwoven created from a blend of cellulosic and polyester and/or polypropylene fibers with an abrasive side. The basis weight can range from 1.2 to 6 ounces per square yard. A composite dual textured material manufactured by Kimberly Clark comprises a coarse meltblown polypropylene, polyethylene, or polyester and high loft spunbond polyester. The two materials can be laminated together using chemical adhesives or by coprocessing the two layers. The coarse meltblown layer can range from 1 to 3 ounces per square yard while the highloft spunbond layer can range from 1 to 3 ounces per square yard. Another example of a composite is a dual textured material composed of coarse meltblown polypropylene, polyethylene, or polyester and polyester/cellulose coform. The two materials can be laminated together using chemical adhesives or by coprocessing the two layers. The coarse meltblown layer can range from 1 to 3 ounces per square yard. The coform layer can range in composition from 30% cellulose and 70% polyester to 70% cellulose and 30% polyester and the basis weight can range from 1.5 to 4.5 ounces per square yard.

The product of the present invention comprising mutliple layers may be ultrasonically bonded after applying the coating of one or more of the layers. Alternatively, layers may be bonded together by needlepunch, thermal bonding, chemical bonding, or sonic bonding prior to applying the coating and/or impregnation.

A multilayer laminate may be an embodiment wherein some of the layers are spunbond and some meltblown such as a spunbond/meltblown/spunbond (SMS) laminate as disclosed in U.S. Pat. No. 4,041,203 to Brock et al. and U.S. Pat. No. 5,169,706 to Collier, et al., each hereby incorporated by reference. The SMS laminate may be made by sequentially depositing onto a moving conveyor belt or forming wire first a spunbond web layer, then a meltblown web layer and last another spunbond layer and then bonding the laminate in a manner described above. Alternatively, the three web layers may be made individually, collected in rolls and combined in a separate bonding step.

In one exemplary process, the substrate comprises a laminate formed by two plies a and b. Both plies a and b are transported in the machine direction. Optionally a glue may be applied to one of the plies a or b by a glue applicator, so that the plies a, b can be consequently joined together. Alternatively, the functional additive may be used to join the plies together, and without using an additional adhesive. During the process, the functional additive is deposited onto the ply a by a functional additive applicator. Then, the plies a, b are joined together at a combining roll such that the functional additive or adhesive is interposed between the two plies a, b. In a multilayer substrate, the generation of a laminate structure can also take place when a film is bonded to another nonwoven layer. The laminate may further be perforated by a perforator, slit into individual sheets by slitters, and wound into the roll, as well known by those skilled in the art. Single layer substrates may also be be perforated by a perforator, slit into individual sheets by slitters, and wound into the roll.

U.S. Pat. No. 6,270,878 to Wegele describes the processing of nonwoven sheets and rolls. Depending upon the desired application, the substrates may be provided as discrete units or may be joined in seriatim by perforations, etc. The substrates may be individually dispensed, such as is commonly done for facial tissues. If individual dispensing is desired, the substrates may be provided in either a reach-in or pop up dispenser, as disclosed U.S. Pat. No. 4,623,074 to Dearwester; U.S. Pat. No. 5,520,308 to Berg. Jr. et al. and U.S. Pat. No. 5,516,001 issued to Muckenfuhs et al., the disclosures of which are incorporated herein by reference. Alternatively, the substrates may be core-wound, as disclosed in U.S. Pat. No. 5,318,235 to Sato, the disclosure of which is incorporated herein by reference. These substrates are pulled from the center of a hollow coreless roll that has perforated sheets. These containers generally have a snap top lid that is opened to expose a piece of the substrates that can then be pulled to remove the desired amount of substrates. If desired, the substrates may be lightly compressed for packaging. Such packaging may be accomplished as disclosed U.S. Pat. No. 5,664,897 to Young et al., the disclosure of which is incorporated herein by reference.

Additional Substrate Components

The substrate may also contain superabsorbent materials. A wide variety of high absorbency materials (also known as superabsorbent materials) are known to those skilled in the art. See, for example, U.S. Pat. No. 4,076,663 issued Feb. 28, 1978 to Masuda et al, U.S. Pat. No. 4,286,082 issued Aug. 25, 1981 to Tsubakimoto et al., U.S. Pat. No. 4,062,817 issued Dec. 13, 1977 to Westerman, and U.S. Pat. No. 4,340,706 issued Jul. 20, 1982 to Obayashi et al. The absorbent capacity of such high-absorbency materials is generally many times greater than the absorbent capacity of fibrous materials. For example, a fibrous matrix of wood pulp fluff can absorb about 7-9 grams of a liquid, (such as 0.9 weight percent saline) per gram of wood pulp fluff, while the high-absorbency materials can absorb at least about 15, preferably at least about 20, and often at least about 25 grams of liquid, such as 0.9 weight percent saline, per gram of the high-absorbency material. U.S. Pat. No. 5,601,542, issued to Melius et al., discloses an absorbent article in which superabsorbent material is contained in layers of discrete pouches. Alternately, the superabsorbent material may be within one layer or dispersed throughout the substrate.

The superabsorbent materials can be natural, synthetic, and modified natural polymers and materials. In addition, the superabsorbent materials can be inorganic materials, such as silica gel, or organic compounds such as cross-linked polymers. The term “cross-linked” refers to any means for effectively rendering normally water-soluble materials substantially water insoluble but swellable. Such means can include, for example, physical entanglement, crystalline domains, covalent bonds, ionic complexes and associations, hydrophilic associations, such as hydrogen bonding, and hydrophobic associations of Van der Waals forces.

Examples of synthetic superabsorbent material polymers include the alkali metal and ammonium salts of poly(acrylic acid) and poly(methacrylic acid), poly(acrylamides), poly(vinyl ethers), maleic anhydride copolymers with vinyl ethers and alpha-olefins, poly(vinyl pyrrolidone), poly(vinylmorpholinone), poly(vinyl alcohol), and mixtures and copolymers thereof. Further superabsorbent materials include natural and modified natural polymers, such as hydrolyzed acrylonitrile-grafted starch, acrylic acid grafted starch, methyl cellulose, chitosan, carboxymethyl cellulose, hydroxypropyl cellulose, and the natural gums, such as alginates, xanthan gum, locust bean gum and the like. Mixtures of natural and wholly or partially synthetic superabsorbent polymers can also be useful in the present invention. Other suitable absorbent gelling materials are disclosed by Assarsson et al. in U.S. Pat. No. 3,901,236 issued Aug. 26, 1975. Processes for preparing synthetic absorbent gelling polymers are disclosed in U.S. Pat. No. 4,076,663 issued Feb. 28, 1978 to Masuda et al. and U.S. Pat. No. 4,286,082 issued Aug. 25, 1981 to Tsubakimoto et al.

Superabsorbents may be particulate or fibrous, and are preferably particulate. Superabsorbents are generally available in particle sizes ranging from about 20 to about 1000 microns. Preferred particle sizes range from 100 to 1000 microns. Examples of commercially available particulate superabsorbents include SANWET® IM 3900 and SANWET® IM-5000P, available from Hoescht Celanese located in Portsmouth, Va., DRYTECH® 2035LD available from Dow Chemical Co. located in Midland, Mich., and FAVOR® 880 available from Stockhausen, located in Sweden. FAVOR® 880 is presently preferred because of its high gel strength. An example of a fibrous superabsorbent is OASIS® 101, available from Technical Absorbents, located in Grimsby, United Kingdom.

Tensile Strength

Sufficient seal strength between laminated layers is important to prevent the layers from peeling off one another. The seal strength is measured using a tensile tester. The tensile tester is a device constructed in such a way that a gradually increasing load is smoothly applied to a defined sample portion until the sample portion breaks. The tensile at the point of breakage (at which time the sample breaks) is frequently called “peak” tensile, or just “peak”. The suitable instrument used for the measurement is Instron 5564, which may be equipped with either digital readout or strip chart data display for load and elongation. The following procedure is conducted under standard laboratory conditions at 23° C. (73° F.) and 50% relative humidity for a minimum of 2.0 hours. (1) Cut a sample into a strip having 1 inch by 5 inches size. At least three strips should be prepared for the measurement. (2) Put the sample strip in the instrument. The way to set the sample strip is to insert the sample strip into the top clamp of the instrument first, and then to clamp the sample strip into the bottom clamp with enough tension to eliminate any slack of the sample strip. (3) Strain the sample strip at 5 inches/minute until breaking it. (4) Read the peak tensile value. (5) Repeat the above procedures (1) to (4) for the other sample strips. (6) Calculate the average tensile as follows: Average Tensile (g/in)=Sum of the peak loads for samples tested divided by the number of test strips tested.

The average tensile value for use herein is the average tensile of the three samples. Calculate and report to the nearest whole unit. The seal strength may be at least 120 g/in, preferably 300 g/in, and more preferably 500 g/in to prevent tearing during use.

Cleaning or Treatment Composition

The substrate may contain a cleaning or treatment composition. The substrate may not contain a cleaning or treatment composition. The treatment composition may comprise surfactants, solvents, additional adjuncts, water or any combination thereof. The treatment composition may be added prior to post-treatment or in a post-treatment operation, such as on the conversion line or in a consumer container.

Surfactants

The cleaning composition may contain one or more surfactants selected from anionic, nonionic, cationic, ampholytic, amphoteric and zwitterionic surfactants and mixtures thereof. A typical listing of anionic, nonionic, ampholytic, and zwitterionic classes, and species of these surfactants, is given in U.S. Pat. No. 3,929,678 to Laughlin and Heuring. A list of suitable cationic surfactants is given in U.S. Pat. No. 4,259,217 to Murphy. Where present, ampholytic, amphotenic and zwitteronic surfactants are generally used in combination with one or more anionic and/or nonionic surfactants.

Solvent

Suitable organic solvents include, but are not limited to, C1-6 alkanols, C1-6 diols, C₁₋₁₀ alkyl ethers of alkylene glycols, C₃₋₂₄ alkylene glycol ethers, polyalkylene glycols, short chain carboxylic acids, short chain esters, isoparafinic hydrocarbons, mineral spirits, alkylaromatics, terpenes, terpene derivatives, terpenoids, terpenoid derivatives, formaldehyde, and pyrrolidones. Alkanols include, but are not limited to, methanol, ethanol, n-propanol, isopropanol, butanol, pentanol, and hexanol, and isomers thereof Diols include, but are not limited to, methylene, ethylene, propylene and butylene glycols. Alkylene glycol ethers include, but are not limited to, ethylene glycol monopropyl ether, ethylene glycol monobutyl ether, ethylene glycol monohexyl ether, diethylene glycol monopropyl ether, diethylene glycol monobutyl ether, diethylene glycol monohexyl ether, propylene glycol methyl ether, propylene glycol ethyl ether, propylene glycol n-propyl ether, propylene glycol monobutyl ether, propylene glycol t-butyl ether, di- or tri-polypropylene glycol methyl or ethyl or propyl or butyl ether, acetate and propionate esters of glycol ethers. Short chain carboxylic acids include, but are not limited to, acetic acid, glycolic acid, lactic acid and propionic acid. Short chain esters include, but are not limited to, glycol acetate, and cyclic or linear volatile methylsiloxanes. Water insoluble solvents such as isoparafinic hydrocarbons, mineral spirits, alkylaromatics, terpenoids, terpenoid derivatives, terpenes, and terpenes derivatives can be mixed with a water-soluble solvent when employed. The solvents are preferably present at a level of from 0.001% to 10%, more preferably from 0.01% to 10%, most preferably from 1% to 4% by weight.

Additional Adjuncts

The cleaning compositions optionally contain one or more of the following adjuncts: stain and soil repellants, lubricants, odor control agents, perfumes, fragrances and fragrance release agents, and bleaching agents. Other adjuncts include, but are not limited to, acids, electrolytes, dyes and/or colorants, solubilizing materials, stabilizers, thickeners, defoamers, hydrotropes, cloud point modifiers, preservatives, and other polymers. The solubilizing materials, when used, include, but are not limited to, hydrotropes (e.g. water soluble salts of low molecular weight organic acids such as the sodium and/or potassium salts of toluene, cumene, and xylene sulfonic acid). The acids, when used, include, but are not limited to, organic hydroxy acids, citric acids, keto acid, and the like. Electrolytes, when used, include, calcium, sodium and potassium chloride. Thickeners, when used, include, but are not limited to, polyacrylic acid, xanthan gum, calcium carbonate, aluminum oxide, alginates, guar gum, methyl, ethyl, clays, and/or propyl hydroxycelluloses. Defoamers, when used, include, but are not limited to, silicones, aminosilicones, silicone blends, and/or silicone/ hydrocarbon blends. Bleaching agents, when used, include, but are not limited to, peracids, hypohalite sources, hydrogen peroxide, and/or sources of hydrogen peroxide.

An effective amount on antimicrobial active may be needed on the substrate depending on the size of the surface to be cleaned and the level of antimicrobial effectiveness desired. Antimicrobial agents include quaternary ammonium compounds and phenolics. Non-limiting examples of these quaternary compounds include benzalkonium chlorides and/or substituted benzalkonium chlorides, di(C₆-C₁₄)alkyl di short chain (C₁₋₄ alkyl and/or hydroxyalkl) quaternaryammonium salts, N-(3-chloroallyl) hexaminium chlorides, benzethonium chloride, methylbenzethonium chloride, and cetylpyridinium chloride. Other quaternary compounds include the group consisting of dialkyldimethyl ammonium chlorides, alkyl dimethylbenzylammonium chlorides, dialkylmethylbenzylammonium chlorides, biguanides, including polyhexamethylene biguanide and mixtures thereof. Additional antimicrobial agents include metallic materials, which bind to cellular proteins of microorganisms and are toxic to the microorganisms are suitable. The metallic material can be a metal, metal oxide, metal salt, metal complex, metal alloy or mixture thereof. Examples of such metals include, silver, zinc, cadmium, lead, mercury, antimony, gold, aluminum, copper, platinum and palladium, their salts, oxides, complexes, and alloys, and mixtures thereof. Additional antimicrobial agents include peroxides and hypohalite compounds and similar compounds that may be provided by a variety of sources, including compounds that lead to the formation of positive halide ions and/or hypohalite ions, as well as bleaches that are organic based sources of halides, such as chloroisocyanurates, haloamines, haloimines, haloimides and haloamides, or mixtures thereof.

The cleaning composition may include a builder or buffer, which increase the effectiveness of the surfactant. A variety of builders or buffers can be used and they include, but are not limited to, phosphate-silicate compounds, zeolites, alkali metal, ammonium and substituted ammonium polyacetates, trialkali salts of nitrilotriacetic acid, carboxylates, polycarboxylates, carbonates, bicarbonates, polyphosphates, aminopolycarboxylates, polyhydroxysulfonates, and starch derivatives. Builders or buffers can also include polyacetates and polycarboxylates. Buffering and pH adjusting agents include organic acids, mineral acids, alkali metal and alkaline earth salts of silicate, metasilicate, polysilicate, borate, hydroxide, carbonate, carbamate, phosphate, polyphosphate, pyrophosphates, triphosphates, tetraphosphates, ammonia, hydroxide, monoethanolamine, monopropanolamine, diethanolamine, dipropanolamine, triethanolamine, and 2-amino-2methylpropanol. When employed, the builder, buffer, or pH adjusting agent comprises at least about 0.001% and typically about 0.01-5% of the cleaning composition. Preferably, the builder or buffer content is about 0.01-2%.

Water

Since the composition is an aqueous composition, water can be, along with the solvent, a predominant ingredient. The water can be present at a level of less than 99.9%, or less than about 99%, or less than about 98%. Deionized water is suitable. Where the cleaning composition is concentrated, the water may be present in the composition at a concentration of less than about 85 wt. %.

Applications

The present invention is suitable for a wide array of dry and wet wipe applications. Surface cleaning wipes work by various means, including but not limited to mechanical abrasive action to loosen soil from a surface, solublization of soil from the lotion in the wet wipe, and collection and entrapment of soil into the structure of the wet wipe. A relatively high friction surface can improve cleaning from surfaces. Wipes can be produced as pre-moistened wet wipes or packaged as dry wipes where the consumer adds a liquid such as lotion or water.

The substrate can be used for cleaning, disinfectancy, or sanitization on inanimate, household surfaces, including floors, counter tops, furniture, windows, walls, and automobiles. Other surfaces include stainless steel, chrome, and shower enclosures. The substrate can be packaged individually or together in canisters, tubs, etc. The substrate can be used with the hand, or as part of a cleaning implement attached to a tool or motorized tool, such as one having a handle. Examples of tools using a substrate include U.S. Pat. No. 6,611,986 to Seals, WO00/71012 to Belt et al., U.S. Pat. App. 2002/0129835 to Pieroni and Foley, and WO00/27271 to Policicchio et al.

Cleaning Implement

In an embodiment of the invention, the substrate is attached to a cleaning implement. In an embodiment of the invention, the cleaning implement comprises the tool assembly disclosed in U.S. Pat. App. 2005/0066465, entitled “Cleaning Tool with Gripping Assembly for a Disposable Scrubbing Head”. Examples of suitable cleaning implements are found in US2003/0070246 to Cavalheiro; U.S. Pat. No. 4,455,705 to Graham; U.S. Pat. No. 5,003,659 to Paepke; U.S. Pat. No. 6,485,212 to Bomgaars et al.; U.S. Pat. No. 6,290,781 to Brouillet, Jr.; U.S. Pat. No. 5,862,565 to Lundstedt; U.S. Pat. No. 5,419,015 to Garcia; U.S. Pat. No. 5,140,717 to Castagliola; U.S. Pat. No. 6,611,986 to Seals; US2002/0007527 to Hart; and U.S. Pat. No. 6,094,771 to Egolf et al. The cleaning implement may have a hook, hole, magnetic means, canister or other means to allow the cleaning implement to be conveniently stored when not in use.

Cleaning Substrate Attachment

The cleaning implement holding the removable cleaning substrate may have a cleaning head with an attachment means or the attachment means may be an integral part of the handle of the cleaning implement or may be removably attached to the end of the handle. The cleaning substrate may be attached by a friction fit means, by a clamping means, by a threaded screw means, by hook and loop attachment or by any other suitable attachment means. The cleaning substrate may have a rigid or flexible plastic or metal fitment for attachment to the cleaning implement or the cleaning substrate may be directly attached to the cleaning implement. Any of these substrates may be water-insoluble, water-dispersible, or water-soluble.

Consumer Containers

The term “container”, refers to, but is not limited to, packets containing one or more individual substrates and bulk dispensers, such as canisters, tubs and jars, which dispense one substrate at a time. The substrates can be maintained over time in a sealable container such as, for example, within a bucket with an attachable lid, sealable plastic pouches or bags, canisters, jars, tubs and so forth. Exemplary resealable containers and dispensers include, but are not limited to, those described in U.S. Pat. No. 4,171,047 to Doyle et al., U.S. Pat. No. 4,353,480 to McFadyen, U.S. Pat. No. 4,778,048 to Kaspar et al., U.S. Pat. No. 4,741,944 to Jackson et al., U.S. Pat. No. 5,595,786 to McBride et al., U.S. Pat. App. 2001/0020632 to De Oliveira et al., U.S. Pat. App. 2001/0055609 to Shantz et al., U.S. Pat. App. 2002/0068142 to Baroni et al., U.S. Pat. App. 2004/0007113 to Morrisey-Hawkins; the entire contents of each of the aforesaid references are incorporated herein by reference. There are two basic types of containers for such wet wipes namely, multiwipe containers and single wipe packages. In typical multiwipe containers, a flexible or rigid moisture impervious container is utilised, the wipes being folded and stacked in such an arrangement therein, so that a single wipe is exposed to and removed by a consumer at one time. These containers have a tub like configuration or a flexible rectangular package, both of which are typically resealable after opening.

Wet wipes have been traditionally dispensed in sheet form from a tub like container with a hinged lid on the top. The lid is opened and individual or singularized sheets of the wipes are removed. Another type of container that has been used for wet wipes provides a roll of wipes in which the wipes are pulled from the top of the container in a direction that is parallel to the axis of the roll. These wipes are pulled from the center of a hollow coreless roll that has perforated sheets. These containers generally have a snap top lid that is opened to expose a piece of the wipes that can then be pulled to remove the desired amount of wipes. Once pulled out the wipes can then be torn off, usually at a perforation, and the lid closed. It is to be understood, however, that cored rolls (hollow cores, solid cores and partially solid cores), hollow coreless rolls, and stacks of sheets may also be used in the dispenser system.

EXAMPLES

During conversion process, the nonwoven substrate is subject to various operations to give it physical integrity, give it suitable physical properties, and provide it in a useful form. For example, the outer cover of fibers can be joined by bonding to form a coherent web structure. Suitable bonding techniques include, but are not limited to, chemical bonding, thermobonding, and processes such as point calendering, hydroentangling, and needling. The substrate may contain two to more layers laminated together at bond sites. In one embodiment, the laminated substrate may be further processed to form apertures in the whole laminate substrate (or portions thereof) by extending portions of the substrate in a direction orthogonal to the axis of bond sites. One method for forming apertures across the substrate is to pass the substrate through a nip formed by incremental stretching system employing opposed pressure applicators having three-dimensional surfaces, which at least to a degree are complementary to one another. Stretching of the laminate substrate may be accomplished by other methods known in the art, including tentoring, or even by hand.

There may optionally be a device for perforating the substrate. The perforation may be accomplished by a pair of rollers, wherein at least one of the rollers comprises a series of teeth or blades such that the impact of the rollers on the substrate results in incisions in a line forming a perforation line. The incisions within the perforation line may be spaced regularly, they may be spaced randomly, or they may be spaced in a controlled arrangement. The perforations are suitably in the cross direction (CD) of the web; that is in the plane of the web perpendicular to the direction of movement, or the machine direction (MD). The perforation may be accomplished by methods known to those skilled in the art. For example, a perforating apparatus as described in U.S. Pat. No. 5,125,302, incorporated herein by reference, may be used to perforate the substrate. The perforating apparatus may contain a rotating perforation roll and a stationary anvil bar. The perforation roll in this case has multiple rows of blades along the CD of the roll, and these blades protrude slightly from the face of the roll. The space between these rows and the length of the blades dictates the perforation length and spacing. The anvil bar is typically configured as a helix, for example a double helix or single helix, such that it contacts the perforation blades only at one or two positions at a time. Thus, as the perforation roll rotates, the substrate becomes perforated across the entire substrate. The substrate typically wraps the rotating perforation roll. The perforating apparatus may contain a rotating anvil roll with a stationary perforation blade. Typically, multiple anvil bars are configured in a helix around the anvil roll and engage the perforation blade. The substrate is perforated in one location at any one time. The substrate does not typically wrap either the anvil roll or the perforation blade. Also, the anvil roll may be kept stationary and the perforation blade may be rotated on a roll.

At the end of a typical conversion process the substate is slit and/or wound. The winding apparatus may be any winding apparatus known to those skilled in the art. The winding apparatus may, for example, wind a substrate around a removable mandrel to produce a coreless material (U.S. Pat. Nos. 5,387,284; 5,271,515; 5,271,137; 3,856,226). The winding apparatus may, for example, wind a substrate around a tubular or cylindrical core (U.S. Pat. Nos. 6,129,304; 5,979,818; 5,368,252; 5,248,106; 5,137,225; 4,487,377). The winding apparatus may, for example, be a coreless surface winder, which can produce coreless rolls without the use of a mandrel. (U.S. Pat. Nos. 5,839,680; 5,690,296; 5,603,467; 5,542,622; 5,538,199; 5,402,960; 4,856,725). The above applications are incorporated herein by reference

The perforating and rewinding of a non-flat rollstock is currently a complicated process. It is typically completed by pulling the Z dimension out of the rollstock and using precise tension control at the conversion operation point. An example would be at the nip of the rotating knives in the case of perforation. The Z dimension is then re-established by the relaxation of the tension on the web and the re-establishing of the original structure due to the previously locked in structure of the fiber bonds that make up the rollstock. The precise tension control and other required system elements and methods are expensive and not always able to be coordinated with the characteristics of the web. A process which avoids having to convert a high drape, flexible nonwoven with a Z dimension to recover after releasing the converting tension would be a significant contributor to machine speed and efficiency. The bond pattern and the subsequent loft or Z dimension details could be tailored for the specific consumer application without regard to the converting line efficiencies. The liquid absorptivity and its correlation to the shape of the generated Z dimension could be developed to meet the current needs of the consumer at point of use delivery and of the lotion loading manufacturing process effectiveness.

In one embodiment, the process described herein would allow the Z dimension to be created in the article after it is perforated and/or rolled. In one embodiment, the process described herein would allow the Z dimension to be created in the article after it is slit into individual units (such as sheets, mitts, diapers) or individual rolls. In one embodiment, final process could be performed after it is placed in its consumer packaging, thus eliminating the need for the complex tension control at the point of conversion. For example, the use of particular bond point patterns in conjunction with nonwoven fibers and webs with dissimilar thermal expansion coefficients that are subjected to heat after conversion could be used to form loft or Z dimension in the web in its final package. In one embodiment, a nonwoven can be formed from materials and bonded with reference points such that it can be perforated, wound into a donut and placed into a canister as a flat rollstock and then can be subjected to treatment, such as heat, such that the thermal expansion rates of the dissimilar components initiate the formation of stresses that force the web and bond points to create a Z dimension (or thickness) in the previously flat wound roll.

In one embodiment, the bond point pattern and the related dissimilarity in the shrinking characteristics of either two separate webs made up individually of fibers with different thermal expansion and contraction characteristics or of an individual web made up of fibers that are commingled in the web forming process that have dissimilar thermal expansion and contraction characteristics that when activated with heat after the web is converted creates wrinkles and puffs that give the web its desired Z dimension. The bond point pattern and the difference in thermal expansion coefficients control the ultimate Z dimension. The amount of heat applied to initiate the thermal contraction of one of the web components and/or the thermal expansion of the other controls the ultimate Z dimension. The magnitude of the difference in the thermal expansion and contraction coefficients controls the ultimate Z dimension. The heat can be applied prior to or after loading of the lotion, and the heat can drive off the volatile component of the active ingredient if the wipe is to be water activated dry wipe application. The heat applied thus would have two functions, to initiate the creation of the Z dimension, and to create a dry wipe or wipe with different lotion properties. If a wet wipe is desired, then the heat must normally be applied prior to the addition of any water or solvent based lotion add on since the shrink temperatures would be usually be higher than the boiling point of water at normal atmospheric pressure. The use of a pressurized chamber would enable the volatile components of the add on to remain stable and associated with the wipe as the heat is added to initiate the shrink and thus the Z dimension as long as the pressure in the chamber is raised in conjunction with an increase in pressure such that the characteristic of the solvent carrying the actives on the wiper stay in the liquid region of the solvent phase equilibrium diagram. An immediate cooling would be required while the pressure is applied and the cooling and release of the pressure would not affect the Z dimension formation as it would be irreversible due to the characteristics of the thermal contraction and expansion of the web components. In an alternative embodiment a vacuum could be applied in addition to heat.

In one example, outer non-shrink layers consisting of woodpulp spunlaced polyester blend, having a 48-62 gsm basis weight, 180-280 micron thickness, greater than 2500 N/m dry MD tensile, 500 N/m dry CD tensile, 2000 N/m wet MD tensile, 400 N/m wet CD tensile, and greater than 300% w/w liquid absorbent capacity were bonded ultrasonically to an inner layer of 100% spunlace polyester absorbent material. The substrates were bonded in a 0.5 inch diamond pattern, a 0.75 inch diamond pattern, and a 1.5 inch triangle pattern. The substrates were also bonded in cross dimension patterns of 0.5 inch, 1.0 inch, and 2.0 inch between bonding lines. In another example, outer non-shrink layers of woodpulp spunlaced polyester blend, having a 48-62 gsm basis weight, 180-280 micron thickness, greater than 2500 N/m dry MD tensile, 500 N/m dry CD tensile, 2000 N/m wet MD tensile, 400 N/m wet CD tensile, and greater than 300% w/w liquid absorbent capacity were bonded to a layer of carded PET using a glue laminator in the cross dimension using a 5 to 1 tension difference between the substates when bonded.

The substrates were wound into rolls and subjected to heating. The rolls were heated in an oven at 400 to 450° F. for 30 to 45 seconds to give an approximate 30% shrink for the shrink layer. For substrates bonded in the cross dimension, the further the bond distance the greater the Z-dimension thickness change. For substrates bonded in a diamond or triangle pattern, the substrate curls to give a Z-dimension thickness change. A laminated structure using the diamond pattern as described in the application exposed to 200 C in an oven for 10 seconds developed a greater than 100% increase in overall thickness.

The rolls could in the same fashion be heated inside consumer canisters or heated as individual items inside packages or heated as sheets inside tubs. The substrate could be sold to the consumer in wet form or dry form.

While various patents have been incorporated herein by reference, to the extent there is any inconsistency between incorporated material and that of the written specification, the written specification shall control. In addition, while the invention has been described in detail with respect to specific embodiments thereof, it will be apparent to those skilled in the art that various alterations, modifications and other changes may be made to the invention without departing from the spirit and scope of the present invention. It is therefore intended that the claims cover all such modifications, alterations and other changes encompassed by the appended claims. 

1. A product combination for delivering a nonwoven product to a consumer comprising; a. a consumer container; and b. a roll of nonwoven substrate; c. wherein the nonwoven substrate has a Z-dimension thickness A when placed in the consumer container; d. wherein the nonwoven substrate is treated in the consumer container to modify the Z-dimension thickness to give a Z-dimension thickness B; e. wherein the Z-dimension thickness B is greater than the Z-dimension thickness A as a result of the treatment operation; and f. wherein the treatment operation is not adding a liquid to the substrate in the consumer container.
 2. The product combination of claim 1, wherein the treatment operation is heating the substrate.
 3. The product combination of claim 1, wherein the heating is provided by microwave energy.
 4. The product combination of claim 1, wherein the substrate is sold to the consumer in dry form.
 5. The product combination of claim 1, wherein the substrate is sold to the consumer in wet form.
 6. A method of increasing the Z-dimension thickness of a nonwoven substrate used for a cleaning wipe comprising: a. slitting the substrate; and b. heating the substrate resulting in a modification of the Z-dimension of the substrate.
 7. The method of claim 6; wherein the substrate is heated in a consumer container resulting in an increase in the Z-dimension thickness of the substrate.
 8. The method of claim 7; wherein the heating is provided by microwave energy.
 9. The method of claim 7; wherein the substrate in the consumer container is in sheet form.
 10. The method of claim 7; wherein the substrate in the consumer container is in roll form.
 11. The method of claim 7; wherein the substrate is individually packaged.
 12. The method of claim 6; wherein the substrate is sold to the consumer in dry form.
 13. The method of claim 6; wherein the substrate is sold to the consumer in wet form.
 14. The method of claim 6; wherein the substrate is heated resulting in an increase in Z-dimension thickness of the substrate before placing the substrate in a consumer container.
 15. The method of claim 6; wherein the consumer heats the substrate.
 16. A method of modifying a specific attribute of a nonwoven substrate comprising: a. placing the substrate in a consumer container; b. treating the substrate to modify the specific attribute; c. wherein the treatment is not adding a liquid to the substrate in the consumer container.
 17. The method of claim 16; wherein the substrate in the consumer container is in sheet form.
 18. The method of claim 16; wherein the substrate in the consumer container is in roll form.
 19. The method of claim 16; wherein the substrate is sold to the consumer in dry form.
 20. The method of claim 15; wherein the substrate is sold to the consumer in wet form. 